APQP, Control Plan, PPAP (according to the latest editions)

Course objectives

The aim of the training is to provide an effective methodology for the application of progressive product or service quality planning methods (project management), for the creation of Control and Management Plans, Process flow documentation and subsequent approval of production parts in terms of the requirements of the latest AIAG manuals: APQP (3rd edition 2024), Control plan (1st edition 2024) and PPAP (4th edition 2009).

Course content

APQP Module

• Time schedule diagram (APQP Product Quality Planning Cycle - Stages)
• PDCA Product Quality Planning Cycle
• Clarification of the content and appendixes of the APQP Manual (3rd edition 2024)
• IATF 16949:2016 Requirements for APQP
• Assembly and organization of the cross-functional team for APQP
• Customer-required inputs and outputs for each stage of the APQP project
• Product and process design and development - feasibility study, product and process validation
• Clarification of the relationship between Process Flow, Process FMEA, and Control Plan documents
• Control Plans (written descriptions of systems for managing parts and processes) for the following stages:
  • Prototype - description of dimension measurements, material and functional property tests performed in the prototype phase
  • Prelaunch - description of dimension measurements, material and functional property tests performed after the prototype phase before mass production
  • Production - documentation of product/process characteristics, process control tools, tests, and measurement systems conducted during "mass" series production.
• Creation of Process Flow and Control Plan documentation (practical examples)

Control Plan Module

• Basics of Control Plan
• Clarification of the content and appendixes of the Control Plan Manual (1st edition 2024)
• Explanation of terms and abbreviations
• Definitions and concepts including key links to APQP and FMEA
• Development of Control Plan
• Phases of Control Plan (prototype, preliminary launch, safe launch, production)
• Effective use of Control Plan (reverse PFMEA, SW, LPA, CP in highly automated processes)

PPAP Module

• Purpose and objectives of the PPAP process in the context of IATF 16949 requirements
• Explanation of terms and abbreviations
• Process requirements (Significant Production Run)
• Customer notification requirements regarding changes and the need for the PPAP process (presentation of examples of specific requirements from Ford, GM, Toyota, PSA, MB)
• Set of 18 key PPAP process requirements/activities
• Levels of submission to the customer / choice of level
• 3 alternatives for customer approval status
• Explanation of documentation/formats according to the PPAP Manual (4th edition 2009) (Ford, Chrysler, General Motors) and VDA 2 guidelines - Quality Assurance of Supplies
• Product quality assurance in series deliveries
• Management of the PPAP process with suppliers
• Practical application

Designed for

• Quality Manager
• Process Engineer
• Production Manager
• Development and Manufacturing Technologist
• Metrologist

Additional information

* UTC +1 time zone (DE, BE, DK, NL, NO, SE, AT, ES, FR, IT, SI, SK, CZ, PL, HU, ...)